Bedding or seating product having filled tube topper

ABSTRACT

A mattress or bedding product is covered with a topper comprising individual tubes, each of which is filled with shredded foam/fiber material. In one embodiment, the topper has a foam layer having a number of arcuate-shaped cradles in which are placed the individual tubes. The shredded foam/fiber materials may be modified as required to provide different density and/or firmness characteristics to different portions of the product.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional PatentApplication No. 60/252,287 filed Nov. 21, 2000 entitled “Tube BedSystem.” This application also claims the benefit of U.S. ProvisionalPatent No. 60/189,169 filed Mar. 14, 2000 entitled “Tube Bed System.”

FIELD OF THE INVENTION

[0002] This invention relates to bedding or seating products in generaland, more particularly, to a bedding or seating product having a topperincorporating tubes filled with filler material.

BACKGROUND OF THE INVENTION

[0003] Various types of bedding products have been developed fromfeather beds to the more modern coil spring mattress which provide acomfortable sleeping surface. Currently, popular coil spring mattressesconsist of coil springs disposed between layers of padding and encasedin a ticking or fabric covering. Various springs are used to createmattresses of different firmness characteristics. The firmness of amattress is generally determined by the firmness of the coil springs inthe spring unit or spring assembly. Additional comfort in a mattress maybe provided by a “pillow top” or “quilt top”. Such a mattress has apillow or quilt material added to one or both of the faces of themattress. The pillow top or quilt top may enclose foam cushions, battingor similar materials to provide an increased loft and comfortable feelto the mattress.

[0004] Known bedding products such as mattresses, including those havinga pillow top or quilt top, are commonly sold as a manufactured unithaving a uniform firmness throughout the mattress such that one zone orregion of the mattress has the same firmness and performancecharacteristics as every other portion of the mattress.

[0005] However, it is commonly recognized in the bedding industry thatcertain regions of a mattress may require different performance orfirmness characteristics to support various areas of the human body. Forexample, the region of the mattress which underlies the torso of a humanbeing supports a substantial portion of the weight of that person;whereas the regions of the mattress which underlie the head and feet arerequired to support less of the weight of an individual. As such, it isdesirable that a mattress or bedding product have multiple zones orregions of differing firmness. The different firmnesses of the zones orregions are commonly due to the characteristics of the springs withinthe different zones or regions. Constructing such a posturized mattressrequires assembling springs having different characteristics such asdifferent thickness, for example, into a spring assembly. This processis more complicated, time consuming and expensive than making a springassembly of identical springs.

[0006] Therefore, it has been a primary objective of this invention toprovide a bedding or seating product which offers the advantages ofstandard coil spring construction while providing multiple zones orregions of different firmness.

[0007] Another objective of the present invention has been to provide atopper having unique firmness characteristics which may be selected by amanufacturer and assembled into a bedding or seating product accordingto the manufacturer's preferences.

SUMMARY OF THE INVENTION

[0008] The present invention which accomplishes these objectivescomprises a bedding or seating product having a conventional springassembly covered by a topper. The topper may cover only one or multiplesurfaces of the spring assembly. A product in which the topper coversonly one surface of the spring assembly is commonly referred to as a onesided product. Similarly, a product in which toppers cover upper andlower surfaces of the spring assembly is commonly referred to as a twosided product. In either event, a fabric covering preferably encasesboth the spring assembly and the topper or toppers.

[0009] The topper of the present invention may assume numerousconfigurations in accordance with the present invention. However, eachof the embodiments of the topper incorporates a plurality of individualtubes oriented in a parallel relationship. Each of the tubes is, atleast partially filled with filler material.

[0010] One embodiment of the present invention incorporates a topperhaving first and second foam layers sandwiching a plurality ofindividual tubes, each at least partially filled with filler material. Afirst or lower foam layer is positioned atop the spring assembly and hasa plurality of generally parallel and arcuate-shaped cradles formed in atop surface of the foam layer. A plurality of individual tubes, each ofwhich is, at least partially filled with filler material, are eachpositioned in one of the cradles of the foam layer and secured theretoby adhesive or the like.

[0011] A second or upper foam layer is positioned atop the individualtubes. The second or upper foam layer has a lower surface in which aplurality of generally parallel and arcuate-shaped cradles are formed,the cradles being sized and adapted to receive the individual filledtubes. Additional foam layers may be placed over the topper if desired.If desired, the upper foam layer may be omitted, in which case thetopper would comprise only the tubes and the lower foam layer.

[0012] The individual tubes are preferably filled with shredded foam andshredded fiber materials. However, they may be filled with solelyshredded pieces of foam or solely with shredded fibers. Other materialssuch as down feathers or wool may be used to fill the individual tubesto the desired firmness.

[0013] The filler materials in some of the tubes may have a differentdensity and/or firmness than the filler materials in other tubes tothereby customize the mattress with different firmness zones. Similarly,the filler materials in some of the tubes maybe different than thefiller materials in other tubes to thereby posturize the mattress withdifferent firmness zones.

[0014] In an alternative embodiment, the individual tubes filled withfiller material are sandwiched between layers of scrim which preferablyis non-woven material but may be other materials as well. The scrimlayers or sheets function to hold the stuffed or filled tubes togetheras well as providing an additional cushioning effect.

[0015] In an alternative embodiment, the individual tubes, at leastpartially filled with filler material, are connected together withfabric strips of non-woven material, woven material or other materials.The fabric strips may be adhesively or otherwise secured to the tubes.

[0016] Advantageously, a variety of different mattress designs withrespect to firmness, loft, feel and other characteristics can beobtained with this invention by inserting selected materials intoselected tubes to provide a posturized product.

[0017] The present invention has multiple applications other than beingutilized on top of a standard spring assembly. For example the topper ofthe present invention may be used with non-coil spring mattresses, boxsprings or as a stand-alone unit by itself or as a replacement for awaterbed insert.

[0018] As such, a bedding or seating product is provided according tothis invention that may be easily adapted or modified at the factory orthereafter to achieve desired firmness characteristics according to aspecific bedding manufacturer's interest or firmness requirements.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The objectives and features of the invention will become morereadily apparent from the following detailed description taken inconjunction with the accompanying drawings in which:

[0020]FIG. 1 is a partially broken-away perspective view of a mattresscomprising a spring assembly and one preferred embodiment of the topperof the present invention encased in a fabric covering;

[0021]FIG. 2 is an exploded view of the mattress of FIG. 1 without thefabric covering;

[0022]FIG. 3 is an exploded view of a mattress without a fabric coveringillustrating another embodiment of the topper of the present invention;

[0023]FIG. 4 is an exploded view of a mattress without a fabric coveringillustrating another embodiment of the topper of the present invention;

[0024]FIG. 5 is an exploded view of a mattress without a fabric coveringillustrating another embodiment of the topper of the present invention;and

[0025]FIG. 6 is a cross-sectional view of one of the individual tubes ofthe topper of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0026] Referring to the drawings, and particularly to FIG. 1, there isillustrated a bedding or seating product 10 incorporating the presentinvention. FIG. 1 illustrates a spring assembly 12 comprising aplurality of aligned, interconnected coil springs 14 as is well known inthe art. The spring assembly 12 may take any one of many known forms andmay include different types of springs, border wires, edge supports,pocketed coil springs or the like known in the bedding industry.

[0027] Referring to FIG. 1, a topper 16 a is positioned atop the springassembly 12. The topper 16 a illustrated in FIGS. 1 and 2 is one ofseveral preferred embodiments of the present invention. A fabriccovering 18 encases the topper 16 a and the spring assembly 12.

[0028] As seen in FIG. 2, topper 16 a comprises a first or lower foamlayer 20 having a number of generally parallel arcuate-shaped cradles 22formed in a top surface 24 thereof. The first foam layer 20 also has agenerally planar lower surface 26 adapted to contact the spring assembly12.

[0029] The cradles 22 are illustrated as extending transversely fromside to side. However, the cradles 22 formed in the first foam layer 20may extend longitudinally (from head to foot) if desired.

[0030] The first foam layer 20 is preferably one piece of foam which maybe any size depending upon the application. However, multiple piecesjoined together may make up the first foam layer 20.

[0031] In one presently preferred embodiment, that of a queen sizemattress, the topper 16 a measures 80 inches in length (L) and 60 inchesin width (W) and has a 2 inch thickness. The transversely extendingcradles 22 are each 1 inch deep, 8 inches wide and extend across theentire width of the first foam layer 20. Four inch wide generally planarend regions 28 at the head and foot of the first foam layer 20 areprovided.

[0032] Positioned atop the first foam layer 20 are a plurality ofindividual tubes 30 adapted to be received inside the cradles 22 of thefirst foam layer 18. As illustrated in FIG. 6 each of the individualtubes 30 is at least partially stuffed with filler material 32. Eachindividual tube 30 comprises a quantity of filler material 32 surroundedby a fabric casing 34. The individual tubes 30 are illustrated extendingfrom side to side, i.e. across the width W of the product asillustrated. However, the individual tubes 30 may extend longitudinally(from head to foot) provided the cradles 22 are similarly oriented.

[0033] The individual tubes 30 may be any size. In one preferredembodiment of the present invention, each tube 30 is approximately 60inches in length and 8 inches in width and may include spaced stitchlines 36 along the length thereof as shown in FIGS. 2-5.

[0034] As illustrated in FIG. 6, the filler material 32 is preferably acombination of shredded foam pieces 38 and shredded fibers 40. Howeverother materials such as down feathers or wool may be stuffed inside thetubes 30. In one preferred embodiment of this invention, each tube 30includes shredded fiber holcore and shredded prime foam having a densityof 1.5 lbs/ft³.

[0035] The quantity and type of filler material 32 inside the tubes 30may be altered as desired to provide the desired firmness of eachindividual tube 30. As such, posturization of the topper can be obtainedby customizing the specific tubes 30 provided in various regions orzones of the unit 10. Alternatively, solid tubes of foam can be utilizedin selected cradles as desired. Different supportive material may beprovided in specific tubes 30 or groups of tubes to provide forposturization and unique lumbar or other body zone region support as isrequired.

[0036] As illustrated in FIG. 1, the bedding product 10 may be dividedinto multiple zones or regions of differing firmness due to thecomposition inside the tubes 30 of the different regions. FIG. 1illustrates a head section 42, a center section 44 and a leg section 46.Although FIG. 1 illustrates three separate longitudinally extendingzones or regions of the product 10, the product 10 may be separated intoany number of longitudinally extending zones or regions in accordancewith the present invention. Alternatively, the tubes 30 of the topper 16a could run longitudinally and the product 10 be separated into aplurality of transversely extending zones or regions due to the firmnesscharacteristics of the tubes within the different zones or regions. Forexample, a mattress could be divided into two regions of differingfirmness, a his region of increased firmness and a her region of lesserfirmness.

[0037] As illustrated in FIG. 2, each tube 30 is preferably secured inone of the respective cradles 22 by deposits of adhesive 50. Thedeposits of adhesive 50 are spaced along the length of the cradles 22 ofthe first foam layer. Other means of securing the tubes 30 in thecradles 22 may be used as well, such as for example ultrasonic welding.

[0038] In the embodiment of topper 16 a illustrated in FIGS. 1 and 2,the tubes 30 are preferably not secured to each other to provide forindependent support and action from one another. However, the tubes 30may be secured to each other if desired.

[0039] As illustrated in FIG. 2, the topper 16a further comprises asecond or upper foam layer 52 positioned or located above the individualtubes 30. The second foam layer 52 has a generally planar upper surface54 and a lower surface 56 in which a plurality of cradles 58 are formed.The cradles 58 are sized so as to receive upper portions of theindividual tubes 30. Preferably, the cradles 58 are the same size as thecradles 22 formed in the first or lower foam layer 20. At the ends ofthe second foam layer 52 generally planar end regions 53 are provided inthe lower surface 56 of the foam layer.

[0040] Surrounding the individual tubes 30 is a foam perimeter made offour individual foam pieces: a pair of transversely extending end pieces62 and a pair of longitudinally extending side pieces 64. The end pieces62 are located above the end regions 28 of the first foam layer 20 andbelow the end regions 53 of the second foam layer 52. All of the foampieces 62,64 are sandwiched between the first and second foam pieces20,52.

[0041] The first and second foam layers 20, 52 and the foam pieces 62,64of the topper 16 a may be any type of foam. One type of foam which hasproven satisfactory is foam type 1850 having a density of 1.8 lbs/ft³and an Indentation Force Deflection (IFD) of 50.

[0042] As illustrated in FIGS. 2, 3 and 5 any of the multipleembodiments of topper of the present invention may be placed on a wiremesh member 66. However, the wire mesh member 66 may be omitted ifdesired, in which case the topper would rest directly on top of thespring assembly 12.

[0043] An alternative preferred embodiment of topper 16 a is illustratedin FIG. 3. In this embodiment, the components of the topper 16 b areidentical to those described above with one addition. An additional foamlayer 68 is provided on top of the second foam layer 52 to provideadditional cushioning. Although the foam layer 68 is illustrated asbeing a unitary piece of foam, this layer may made of multiple pieces offoam or other materials.

[0044] As shown in FIG. 3, the topper 16 b may be placed atop a mattress70 having a base 71, as is conventional in box springs. Regardless ofthe base, the present invention provides a high-loft, high-comfortbedding product which can be individualized by a selection of specifictube materials and associated firmness for a posturized effect. In factany of the topper embodiments illustrated or described in thisapplication may be used with a box spring or equivalent structure.Additionally, any of the toppers of the present invention could beutilized by itself as a standard mattress or as a replacement for awaterbed insert.

[0045]FIG. 4 illustrates an alternative embodiment of the presentinvention. In this embodiment, the topper 16 c comprises a plurality oftubes 30 which are glued, ultrasonically welded or otherwise secured toa lower scrim sheet 72. The lower scrim sheet 72 is preferably made ofnon-woven material but may be made of any other material.

[0046] In order to further hold the tubes 30 in place, a plurality offabric strips 74 extend across the tops of the tubes. The fabric strips74 are preferably glued to the upper surfaces of the tubes 30 but may beultrasonically welded or otherwise secured thereto. The fabric strips 74extend perpendicular to the longitudinal direction of the tubes 30.Although three fabric strips 74 are illustrated, any number of fabricstrips 74 may be used. Additionally, in place of a lower scrim sheet 72,fabric strips 74 may be secured to lower surfaces of the tubes 30 inorder to hold the tubes in place.

[0047] This embodiment of the present invention incorporating a topper16 c obviates the need for the foam layers illustrated in FIGS. 1 and 2because the tubes are held in place with the fabric strips 74 and lowerscrim sheet 72. Additionally foam blocks 62,64 illustrated in FIGS. 2and 3 are not necessary although they may be used in this embodiment.

[0048]FIG. 5 illustrates another embodiment of the present invention. Inthis embodiment, topper 16 d is located above a spring assembly 12 andwire mesh member 66 as described above. The topper 16 d comprises alower scrim sheet 76 and upper scrim sheet 78 sandwich a plurality oftubes 30 therebetween. Although the tubes 30 are illustrated asextending transversely, they may extend longitudinally. The scrim sheets76, 78 and tubes 30 form a topper 16 d which is placed on top of thewire mesh member 66 and spring assembly 12. The topper 16 d comprises aplurality of tubes 30 which are glued, ultrasonically welded orotherwise secured to the upper and lower scrim sheets 78, 76. The scrimsheets are preferably made of non-woven material but may be made of anyother materials.

[0049] From the above disclosure of the general principles of thepresent invention and the preceding detailed description of at least onepreferred embodiment, those skilled in the art will readily comprehendthe various modifications to which this invention is susceptible.Therefore, we desire to be limited only by the scope of the followingclaims and equivalents thereof.

We claim:
 1. A bedding or seating product comprising: a spring assembly;a topper located on one surface of the spring assembly, said toppercomprising a plurality of individual generally parallel tubes, each ofsaid tubes having filler material therein; and a fabric coveringencasing said spring assembly and said topper.
 2. A bedding or seatingproduct comprising: a spring assembly; and a topper located on onesurface of the spring assembly, said topper comprising a plurality ofindividual tubes joined together, each of said tubes having fillermaterials therein.
 3. The product of claim 2 wherein scrim sheets joinsaid individual tubes together.
 4. The product of claim 2 wherein fabricstrips join said individual tubes together.
 5. The product of claim 2wherein said filler materials comprise shredded foam and shreddedfibers.
 6. The product of claim 2 wherein the filler materials in afirst portion of the topper have a different density and/or firmnessthan the filler materials in a second portion of the topper to providethe topper with different firmness zones.
 7. A mattress comprising: aspring assembly; a foam layer positioned atop the spring assembly andhaving a plurality of generally parallel arcuate shaped cradles formedin a top surface of the foam layer; and a plurality of individual tubeseach secured in one of said cradles, each of said tubes having fillermaterials therein.
 8. The mattress of claim 7 wherein the fillermaterials in select tubes have a different firmness than the fillermaterials in other of said tubes to provide the mattress with differentfirmness zones.
 9. The mattress of claim 7 further comprising a secondfoam layer positioned atop the tubes.
 10. The mattress of claim 7further comprising: a second foam layer positioned atop the plurality ofindividual tubes, a bottom surface of the second foam layer having aplurality of generally parallel arcuate shaped cradles, one of the tubesbeing positioned in each of the second foam layer cradles.
 11. Themattress of claim 7 wherein said filler materials include shredded foam.12. The mattress of claim 7 where in said filler materials includeshredded fibers.
 13. A bedding or seating product comprising: a springassembly having a plurality of springs; a topper positioned atop thespring assembly, said topper comprising a plurality of individual tubeseach of which has shredded materials therein; and upper and lower scrimsheets secured to said tubes.
 14. The product of claim 13 wherein saidtubes are adhesively secured to said scrim sheets.
 15. The product ofclaim 13 wherein the shredded materials in a first portion of the tubeshave a different density and/or firmness than the shredded materials ina second portion of the tubes to provide the mattress with differentfirmness zones.
 16. The product of claim 13 further comprising a meshmember extending across a top surface of the spring assembly.
 17. Theproduct of claim 13 wherein said shredded materials include shreddedfoam.
 18. The product of claim 13 wherein said shredded materialsinclude shredded fibers.
 19. A bedding or seating product comprising: aspring assembly; and a topper positioned atop the spring assembly, saidtopper comprising a plurality of individual tubes each of which hasshredded materials therein, said tubes being joined together with stripsof fabric.
 20. The product of claim 19 wherein said strips of fabric areadhesively secured to said tubes.
 21. The product of claim 19 whereinsaid shredded materials include shredded foam.
 22. The product of claim19 wherein said shredded materials include shredded fibers.
 23. A topperfor use in a bedding product having a spring assembly, said toppercomprising: a foam layer positioned atop the spring assembly and havinga plurality of generally parallel arcuate shaped cradles formed in a topsurface of the foam layer; and a plurality of individual tubes eachsecured in one of said cradles, each of said tubes having fillermaterials therein.
 24. The topper of claim 23 further comprising asecond foam layer located atop the individual tubes, said second foamlayer having a plurality of generally parallel arcuate shaped cradlesformed in a lower surface of the foam layer.
 25. The topper of claim 23further comprising a second foam layer located atop said individualtubes.
 26. The topper of claim 23 wherein the filler materials in afirst portion of the topper have a different firmness than the fillermaterials in a second portion of the topper to provide the topper withdifferent firmness zones.
 27. A topper for use in a bedding product,said topper comprising: a plurality of parallel individual tubes joinedtogether with at least one scrim sheet, each of said tubes havingshredded foam and shredded fiber materials therein.
 28. The topper ofclaim 27 wherein the shredded foam and shredded fiber materials in afirst portion of the topper have a different firmness than the shreddedfoam and shredded fiber materials in a second portion of the topper toprovide the topper with different firmness zones.
 29. A topper for usein a bedding product, said topper comprising: a plurality of parallelindividual tubes joined together with a plurality of fabric strips, eachof said tubes having shredded materials therein.
 30. The topper of claim29 wherein the shredded materials in a first portion of the topper havea different firmness than the shredded materials in a second portion ofthe topper to provide the topper with different firmness zones.